Kemppi MinarcTig 180MLP User manual

1
Service manual
MinarcTig 180MLP
Version 1.0
180MLP
MinarcTig

2
Table of contents
Technical data......................................................................................3
Main circuit diagram........................................................................... 4
Block diagram..................................................................................... 5
Main circuit card Z001
Operating diagram............................................................... 6
Connectors........................................................................... 7
Measurings...........................................................................8
Control card A001
Operating diagram............................................................... 9
Connectors........................................................................... 10
Spark generator card A002
Connectors / operating diagram..........................................11
Panel card P001
Connectors / operating diagram..........................................12
Operating panel................................................................................... 13
Setup....................................................................................................14
Setup functions....................................................................................15-17
Error codes...........................................................................................18
Structure.............................................................................................. 19
Power semiconductors testing and replacing...................................... 20
Programming.......................................................................................21
Troubleshooting...................................................................................22

3
Technical data
Mains voltage 1 ~230 V ±15%, 50 / 60 Hz
TIG
MMA Max. 6,7 kVA (180 A / 17,2 V) Max. 7,0 kVA (140 A / 25,6 V)
180 A / 17,2 V
120 A / 14,8 V
140 A / 25,6 V
100 A / 24 V
Supply current, I1max TIG
MMA 29 A (180 A/17,2 V) 31 A (140 A/25,6 V)
Fuse 16 A delayed
TIG 35 % ED 180 A/17,2 V
100 % ED 120 A/14,8 V
MMA 35 % ED 140 A/25,6 V
100 % ED 100 A/24 V
Welding range TIG
MMA 5 A/10,2 V-180 A/17,2 V 10 A/20,4 V-140 A/25,6 V
Idle Power TIG
MMA - 25 W
MMA welding electrodes MMA Ø1,5-3,25 mm
Load capacity
Supply current, I1eff TIG
MMA 18 A (120 A/14,8 V) 22 A (100 A/24,0 V)
Connection cable / fuse 3 x 2,5 mm² - 3 m Euro Schuko
Open circuit voltage 95 V
Power ratio at max. current TIG / MMA 0,62 / 0,63
Efficiency at max. current TIG / MMA 0,75 / 0,81
Spark voltage 7-13 kV
External dimensions(L x W x
H) (400 x 180 x 340) mm
Weight 7,8 kg (8,4 kg with supply cable)
Degree of protection IP 23 C
Operating temperature range - 20 °C…+ 40 °C
Recommended generator > 7 kVA
TIG 35 % ED
100 % ED
MMA 35 % ED
100 % ED
Rated power
Load capacity

4
Main circuit diagram
Solenoid valve, Y001 Fan, M001
Main switch, S1
Spark transformer, T003
Choke, L002Main transformer, T001
Aux. transformer, T002
Shunt resistor, R001
PTC, 140 °C
PTC, 120 °C
Control card
Main circuit card
Spark generator card, A002
Panel card, P001

5
Block diagram
Control card A001
Aux. Voltage development
Undervoltage monitoring
Over voltage monitoring
Temperature monitoring
Solenoid valve control
Fan control
Power supply control
Main circuit card Z001
Net over voltage protection
DC-link charging
EMI-filter
Primary rectifier
Energy reserve
”Dual-forward”-inverter
Main transformer
Secondary rectifying
Panel card P001
Adjustment potentiometer
Parameters selection
Overheat protection signal light
Main switch signal light
Spark generator card A002
” Spark voltage generator
(=voltage multiplier)
Spark voltage adjustment

6
Main circuit card Z001
Secondary rectifier
Current transformer,
T1
DC-link charging,
resistors and relay
EMI-filter
IGBTs, gate
resistors, return
current diodes
Main transformer,
T001
Smoothing capasitors
Primary rectifier
Connector to A001
Operating diagram
- Net over voltage
protection
- DC-link charging
-EMI-filter
- Primary rectifier
-Energyreserve
- Dual-forward-inverter
- Main transformer
- Secondary rectifier
Z001

7
Connectors
X16 X5 X1
X12
X2
X3
X11
X15
X14
X13
X9
X10
X4
C
B
A
X1 Power supply voltage 230 Vac
X2 Connector A001
X3 Power supply voltage 230 Vac
X4 Shunt resistor, (-)
X5 Machine body, equipment earth
X9 Aux. transformer T002 supply voltage ~230 Vac
X10 Aux. transformer T002 supply voltage ~230 Vac
X11 Supply voltage to spark generator card A002
Z001 connectors
X12 Supply voltage to spark generator card A002
X13 Secondary choke L002, (+)
X14 PTC, main transformer
X15 PTC, main transformer
X16 Machine body, equipment earth
Measuring point A. X1, X3
Measuring point B. X2/6, X2/12
Measuring point C Primary rectifier

8
Measurings
Measuring point A.
Supply voltage, main circuit card Z001 Measuring point B.
Gate control pulse (X2/6, X2/12), no load
Measuring point C.
DC-link charging (primary rectifier)

9
Control card A001
X13X14
X9
X8
X3
X2
X1
X5
X6
H2
H1
Operating diagram
- Aux. Voltage development
- PWM-control
- Shunt amplifier
- MMA dynamic control
- Solenoid valve control
- Fan control
- Under voltage watch
- Overvoltage watch
- Overheat watch
- Remote/foot control interface
- TIG –torch interface
- Panel interface
- Filtering of control lines

10
Connectors
X1/1 I2 measure
X1/2 U2 measure
X1/3 D1 data
X1/4 D1 data
X1/5 D1 data
X1/6 Torch potentiometer
X1/7 Remote potentiometer
X1/8 Current control
X1/9 D2 data
X1/10 D2 data
A001 / X1
X1/11 D2 data
X1/12 Dynamics
X1/13 Powersource type
X1/14 Pedal start
X1/15 + 5 V
X1/16 GND
X2/1 GND
X2/2 Relay + 24 V
X2/3 -
X2/4 PTC
X2/5 -
X2/6 Gate control
X2/7 Overvoltage, opto
X2/8 Relay on/off
X2/9 U2 measure
X2/10 PTC
A001 / X2
X2/11 -
X2/12 Gate control
X3/1 PTC
X3/2 PTC
A001 / X3
X5/1 GND
X5/2 -
X5/3 24 V
X5/4 Pedal start
X5/5 Remote pot
X5/6 -
X5/7 + 5 V
A001 / X5
X6/1 GND
X6/2 SW 1
X6/3 SW 2
X6/4 Start
X6/5 Potentiometer
X6/6 -
X6/7 + 5 V
A001 / X6
X8/1 21 Vac
X8/2 GND
A001 / X8
X9/1 I1 measure
X9/2 I1 measure
A001 / X9
X13/1 24 V
X13/2 GND
A001 / X13
X14/1 Spark on / off
X14/2 Solenoid valve (+)
X14/3 -
X14/4 Spark on / off
X14/5 Solenod valve (-)
X14/6 -
A001 / X14
H1 Aux. voltage + 5 V (LED)
H2 Aux. voltage + 24 V (LED)

11
Spark generator card A002
Connectors
R9
X2
X1
X3 X1 Main transformer secondary
X2 Spark on / off
X3 Spark transformer primary
R9 Spark voltage adjustment
A002 connectors
Operating diagram
- Spark voltage generator
(=voltage multiplier)
- Spark voltage adjustment

12
Panel card P001
Connectors
X3
X2 X10
X1
X1 Connector A001
X2 Membrane panel connection
X10 Program-/service channel
P001 Connectors
Operating diagram
- Micro controller (Renesas M30262)
- Adjustment potentiometer
- Parameters selection
- Overheat protection signal light
- Main switch signal light

13
Operating panel
2T / 4T function and
minilog
Process
selection TIG /
MMA
Selection arrow
keys
Pregas
Upslope
Standby
indicator Overheating indicator
Downslope
Postgas
Panel / remote
selector
Control knobb
Pulse on/off
HF ignition ( LED on )
Contact ignition ( LED off )
Minilog Pulse cycle

14
Setup
1
2
4
3
•You can enter the Setup mode by pressing both arrow
keys ( 1 ) for at least five seconds.
•The display will show the name of the parameter ( 2 ) and
numerical value ( 3 ).
•Select the parameter to be adjusted with the arrow buttons
( 1 ), and change value with the control knob ( 4 ).

15
Setup functions
Electrode ignition pulse. -9=No pulse, 0=Max pulse0-9 … 0t
Arc dynamics (Arc Force)0-3 … 5S
Maximum setting of post-gas time.30s15 … 99so
Maximum setting of pre-gas time.10.0s5.0 … 20.0sL
J
h
F
E
d
C
B
A
Name on
display
1.0s
0s
0
20%
1
0
0
0
Factory
setting
Forced stop during downslope with a brief pressing of the switch. 1=On, 0=Off0 or 1
Alternative switch logic. 0=4T LOG, 1=Minilog,( 2=4T-LOG+Minilog, 3= Minilog+ search arc )0,1,2 or 3
Start current level as %of the welding current.5 … 40%
Restore factory settings. 1=Restore, 0=No restore0 or 1
Minimum setting of pre-gas time.0.0 … 2.0s
Minimum setting of post-gas time.
Open-circuit voltage selection. 1=30V (VRD), 0=95V
End current level selection. 1=5A, 0=15%
Description
0.0 … 10.0s
Parameter
value range
0 or 1
0 or 1
( Available from program version 0A7 )

16
Setup functions
A = End current level selection
With this function you can set the welding current level when the arc will be extinguished.
0 = 15% of the welding current that is used.
1 = minimum current, which is 5 amperes in this power source.
B = Open-circuit selection
With this function you can change the open-circuit voltage.
0 = 95 volts
1 = 30 volts
C = Forced stop during downslope with a brief pressing on the switch
When downslope time is adjusted, the welding current drops normally to the
end current level and the arc is extinguished. This function allows to stop the arc during
the downslope with a quick press from the switch. Works only with 2T.
0 = Off
1 = On
d = Alternative switch logic
With this function it is possible to choose between four different switch logics.
0 = 4T-LOG
1 = Minilog
2 = 4T-LOG + Minilog
3 = Minilog + Search arc
E = Start current level selection (% of the welding current)
With this function you can set the current level when the arc ignites.
The value is a percentage of the welding current. The factory setting is 20%.
If the welding current is set to 100A, the start current level is 20A.
The adjustment range is 5–40%.
F = Restore factory settings
With this function you can reset the parameters to the factory settings.
0 = Do not restore factory settings
1 = Restore factory settings

17
Setup functions
h = Minimum setting for pre-gas time
With this function you can set the pre-gas minimum time to the desired
value in the range 0 – 2 seconds.The factory setting is 0 seconds.
J = Minumum setting for post-gas time
With this function you can set the post-gas minimum time to the desired
value in the range 0 – 10 seconds.The factory setting is 1 second
L = Maximum setting for pre-gas time
With this function you can set the pre-gas maximum time to the desired
value in the range 5 – 20 seconds. The factory setting is 10 seconds.
o = Maximum setting for post-gas time
With this function you can set the post-gas maximum time to the desired
value in the range 15 – 99 seconds. The factory setting is 30 seconds.
S=Arcdynamics(ArcForce)
When welding with MMA the power source automatically adjusts the dynamics.
With this function it is possible to adjust the dynamics manually.
Adjustment range is -3 - +5
-3 = ( softer arc )
+5 = ( harder arc )
t = Electrode ignition pulse
When welding with MMA the power source automatically adjusts the ignition pulse.
With this function it is possible to adjust the ignition pulse manually.
Adjustment range is -9 – 0
-9 = No ignition pulse
0 = Maximum ignition pulse

18
Error codes
E2: Power source undervoltage
The machine has stopped because it has detected a mains undervoltage that disturbs welding.
Check the quality of the supply network.
E3: Power source overvoltage
The machine has stopped the welding because it has detected momentary voltage spikes or
continuous overvoltage dangerous to the machine in the electric network.
Check the quality of the supply network
E4: Power source overheating
The power source has overheated. The cause may be one of the following.
The power source has been used for a long time at maximum power
The circulation of cooling air to the power source is blocked
The cooling system has experienced a failure
Notice !
Remove any obstacle to air circulation, and wait until the power source fan has cooled down
the machine.

19
Structure
Main switch, S001
Solenoid valve,
Y001
Fan, M002
Control card, A001
Spark generator card,
A002
Panel card, P001
Aux. transformer, T002
Membrane panel
Main circuit card, Z001 Choke, L002
Shunt resistor,
R001
Spark transformer, T003
Main
transformer,
T001

20
Power semiconductor testing and replacing
A separate discrete-IGBTs can be tested only when disconnected
from the board with IGBT-tester.
When replacing damaged IGBTs, the whole set has to be
replaced, including gate resistors!!
Discrete-IGBT and secondary diodes tightening torque to the heat
sink is 0,6…1,2 Nm.
GCE
IGBT-TESTER
TR1TR2
CONTROL
OFFON
B2/6
C2E1/1
E2/2
C1/3
B1/4